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The application of induction hardening treatment plays a vital role for enhancing fatigue life of various automotive components. This will incorporate compressive residual stresses in the component at significant extent. In this paper, wide range of experiments have been carried out on Rotating Bending Fatigue (RBF) specimens made from 38MnVS6 micro alloyed steel with induction hardening up to three different case depths. The set of specimens are fatigue tested at fully reverse loading condition using rotating bending fatigue testing machine. Based on this study a surface treatment factor is evaluated. This surface treatment factor is used as an input for evaluating precise fatigue life of the specimen using FEA packages. The fatigue life evaluated using FEA is showing good agreement with the results obtained through tests on the actual specimens.

In the current scenario of automotive industries, designers are focusing on the development of lightweight, compact and high pressure engines. This demands downsizing of the engine components without compromising its strength. Crankshaft design is crucial in deciding the engine efficiency along with higher strength to weight ratio. Hence, the precise knowledge on crankshaft bending and torsion rigidity is required at design stage. This greatly influences on life performance of crankshaft, engine block and bearing. The study aims at a) Evaluation of crankshaft bending rigidity by Finite Element Analysis (FEA) and its experimental validation, b) Study the effect of crankshaft orientation on bending rigidity and c) Evaluate most critical geometric parameters of the crankshaft (Crankpin and Journal diameter, Pin and Journal width, Throw, Web thickness and Web width) and their quantitative contribution to bending rigidity.

Automotive industries are using forged crankshafts for higher performance applications due to its high strength. Torsional rigidity plays an important role in the performance of crankshaft. The improved torsional rigidity of a forged crankshaft provides better torsion strength and improves engine performance. Present competitive market demands fast product development with lower cost and light weight design while maintaining fatigue strength and other functional requirements. The study aims: a) evaluation of crankshaft torsion rigidity by analytical method and its Finite Element Analysis (FEA) correlation, b) evaluation of twist angle using virtual testing and its correlation with test bench data c) evaluate most critical geometric parameters of crankshaft (Crankpin diameter, Pin width, Throw, Web thickness and Web width) and their quantitative contribution in torsional rigidity.